BR10 - Use of Bauxite Residue Slurry As Single Activator in A Hybrid Binder System

USE OF BAUXITE RESIDUE SLURRY AS
SINGLE ACTIVATOR IN A HYBRID BINDER

SYSTEM
Lukas Arnout1, Tobias Hertel1, Maxime Liard2,

Didier Lootens2, Yiannis Pontikes1
1
KU Leuven, Department of Materials Engineering, Leuven, Belgium
2
Sika Technology AG – Central Research, Zürich, Switzerland
Presented by: Tobias Hertel

ICSOBA Hamburg, 2 – 5 October 2017
1
Presenter’s Bio
• Name: Tobias Hertel
• Degrees and date earned: Master of Science in Applied

Mineralogy, September 2014
• Affiliation: Department of Materials Engineering, KU Leuven

(Belgium)
• Present position: PhD Candidate (EU Marie Curie REDMUD

Project), since May 2015
• Work experience: 7 months research assistant, in cement

group, Department of Mineralogy, University of
Erlangen/Nuremberg (Germany)

2
Introduction
Bauxite Res
idue as a res
ource
Metal recovery
Construction Materials
 High volume valorisation

3
Introduction
Use in geopolymers/inorganic polymers
(ferro)aluminosilicate source
(mainly amorphous, glassy phase)
Mainly crystalline phases,

-Si-O-Al-O-Fe-
No reactive glass phase
Alkali-
(silicate)
solution
→ Use mainly as filler material with other reactive
Inorganic Polymer components
→ Higher content of BR, lower properties

4
Introduction
What abou
t t he l i q ui d
fraction?
Alkali-(silicate) solution Inorganic Polymer

-Si-O-Al-O-Fe-
Hybrid binders
Cement (with cement additions)

5
Preparation of hybrid cements
Activator
Solid fraction
Non ferrous metallurgical
slag (NFMS)
BR slurry Solid activator
Workability aids
Ground granulated blast NaOH

furnace slag (GGBFS)
Cement
CaSO40.5H2O
plasticizer

6
Materials
Ca2SiO4
100 wt%
97 wt% Ca3SiO5
amorphous
amorphous
Ground granulated
Non ferrous blast furnace slag Ordinary Portland
metallurgical slag (GGBFS) Cement
(NFMS) (OPC)
Oxide wt% Oxide wt%

Oxide wt%
FeO 0.6 Fe2O3 4.9
FeO 43.3
SiO2 33.1 SiO2 20.7
SiO2 35.2
CaO 38.2 CaO 64.2
CaO 11.7
Al2O3 13.7 Al2O3 3.5
Al2O3 4.9
MgO 8.2 MgO 0.9
MgO 2.7
(K,Na)2O 0.8 (K,Na)2O 0.6
(K,Na)2O 0.5
TiO2 1.1 TiO2 0.2
TiO2 0.5
SO3 2 SO3 2.3
7
Materials
BR slurry
L/S = 0.7
Liquid fraction Element ppm

pH 12.8 Na 2502
Dry fraction Al 1052
Na content ~ Si 4
Oxide wt%
0.11 M NaOH Ca 3
Fe2O3 43.6
SiO2 11.7
CaO 5.5
Al2O3 19.3
Na2O 8.8
TiO2 9.1

8
Paste composition in wt%
Sample BR slurry GGBFS NFMS CEM I NaOH CaSO40.5H2O plasticizer
GGBFS-B 41 58 0.5 0.8
GGBFS-OPC
GGBFS-Na
GGBFS-OPC-Na
NFMS-B 33 66 0.4 0.7
NFMS-OPC
NFMS-Na
NFMS-OPC-Na

9
GGBFS-B 41 58 0.5 0.8
GGBFS-OPC 41 49 8.2 0.5 1.3
GGBFS-Na
GGBFS-OPC-Na
NFMS-B 33 66 0.4 0.7
NFMS-OPC 33 59 6.6 0.4 1.1
NFMS-Na
NFMS-OPC-Na

10
GGBFS-B 41 58 0.5 0.8
GGBFS-OPC 41 49 8.2 0.5 1.3
GGBFS-Na 40 56 0.8 0.5 1.9
GGBFS-OPC-Na
NFMS-B 33 66 0.4 0.7
NFMS-OPC 33 59 6.6 0.4 1.1
NFMS-Na 32 65 0.6 0.4 1.6
NFMS-OPC-Na

11
GGBFS-B 41 58 0.5 0.8
GGBFS-OPC 41 49 8.2 0.5 1.3
GGBFS-Na 40 56 0.8 0.5 1.9
GGBFS-OPC-Na 40 49 8.1 0.8 0.5 1.6
NFMS-B 33 66 0.4 0.7
NFMS-OPC 33 59 6.6 0.4 1.1
NFMS-Na 32 65 0.6 0.4 1.6
NFMS-OPC-Na 33 59 6.5 0.7 0.4 1.3

12
Heat flow calorimetry
GGBFS samples
10
Evaluation of reactivity over time
9
Heat rate paste (mW/g)
0
0 10 20 30 40 50 60 70 80 90 100
GGBFS-B (H 72 = 40 J/g)
Time (h)
GGBFS-OPC (H 72 = 100 J/g)
GGBFS-Na (H 72 = 245 J/g) GGBFS-OPC-Na (H 72 = 260 J/g)

13
Heat flow calorimetry NFS samples
5
Heat rate paste (mW/g)
0
0 10 20 30 40 50 60 70
Time (h)
NFMS-B (H 72 = 10 J/g) NFMS-OPC (H 72 = 130 J/g)
NFMS-Na (H 72 = 10 J/g) NFMS-OPC-Na (H 72 = 200 J/g)

14
Mechanical strength
Conventional binder
Ordinary Portland Cement:
Strength after 2 d: >10 MPa >20 MPa
Strength after 28 d: >32 MPa >52 MPa

15
Initial Mechanical Strength – Samples with GGBFS
45.0
28 d
GGBFS-B GGBFS-OPC
40.0
GGBFS-Na GGBFS-OPC-Na 78 MPa
Compressive strength (MPa)
35.0
64 MPa
30.0
25.0
32 MPa
>20 MPa
20.0
15.0
10.0 >10 MPa
5.0
14 MPa
0.0
0 10 20 30 40 50 60 70 80
Time (h)
16
Initial Mechanical Strength – Samples with NFS
45.0 28 d
NFMS-B NFMS-OPC
40.0
67 MPa
NFMS-Na NFMS-OPC-Na
35.0
30.0
25.0
20.0 >20 MPa
15.0
> 10 MPa 43 MPa

10.0
5.0 14 MPa
0.0 6 MPa
0 10 20 30 40 50 60 70 80
Time (h)
17
Mechanical Strength after 28 d
90
80
70
60
>52 MPa
50
40>32 MPa
30
20
10
0
…B ...OPC ...Na ...OPC-Na
GGBFS NFMS

18
Conclusion - Outlook
• 30 – 40 wt% BR slurry is used as activator for slags
• in combination with cement or NaOH higher compressive strengths

are measured
• Possibility to increase BR content by replacing slags by modified

BR slag

19
Thank you very much for your attention
USE OF BAUXITE RESIDUE SLURRY AS SINGLE ACTIVATOR IN A HYBRID BINDER SYSTEM
Lukas Arnout, Tobias Hertel, Maxime Liard, Didier Lootens, Yiannis Pontikes
Tobias Hertel – Ph.D. candidate (H2020 ETN-MSCA Redmud Project)

KU Leuven, Department of Materials Engineering,
SREMat research group Secondary Resources for Engineered Materials
Kasteelpark Arenberg 44, 3001 Leuven, Belgium
Tel.: +32 163 747 96
Tobias.Hertel@kuleuven.be
https://www.mtm.kuleuven.be/Onderzoek/sremat
http://etn.redmud.org/

20

BR10 - Use of Bauxite Residue Slurry As Single Activator in A Hybrid Binder System

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USE OF BAUXITE RESIDUE SLURRY AS

SINGLE ACTIVATOR IN A HYBRID BINDER

Lukas Arnout1, Tobias Hertel1, Maxime Liard2,

Presented by: Tobias Hertel

• Degrees and date earned: Master of Science in Applied

• Affiliation: Department of Materials Engineering, KU Leuven

• Present position: PhD Candidate (EU Marie Curie REDMUD

• Work experience: 7 months research assistant, in cement

ICSOBA Hamburg, 2 – 5 October 2017

ICSOBA Hamburg, 2 – 5 October 2017

Use in geopolymers/inorganic polymers

Mainly crystalline phases,

→ Higher content of BR, lower properties

ICSOBA Hamburg, 2 – 5 October 2017

Alkali-(silicate) solution Inorganic Polymer

ICSOBA Hamburg, 2 – 5 October 2017

Ground granulated blast NaOH

ICSOBA Hamburg, 2 – 5 October 2017

Oxide wt% Oxide wt%

Liquid fraction Element ppm

ICSOBA Hamburg, 2 – 5 October 2017

Paste composition in wt%

Sample BR slurry GGBFS NFMS CEM I NaOH CaSO40.5H2O plasticizer

GGBFS-B 41 58 0.5 0.8

NFMS-B 33 66 0.4 0.7

ICSOBA Hamburg, 2 – 5 October 2017

Paste composition in wt%

Sample BR slurry GGBFS NFMS CEM I NaOH CaSO40.5H2O plasticizer

GGBFS-B 41 58 0.5 0.8

GGBFS-OPC 41 49 8.2 0.5 1.3

NFMS-B 33 66 0.4 0.7

NFMS-OPC 33 59 6.6 0.4 1.1

ICSOBA Hamburg, 2 – 5 October 2017

Paste composition in wt%

Sample BR slurry GGBFS NFMS CEM I NaOH CaSO40.5H2O plasticizer

GGBFS-B 41 58 0.5 0.8

GGBFS-OPC 41 49 8.2 0.5 1.3

GGBFS-Na 40 56 0.8 0.5 1.9

NFMS-B 33 66 0.4 0.7

NFMS-OPC 33 59 6.6 0.4 1.1

NFMS-Na 32 65 0.6 0.4 1.6

ICSOBA Hamburg, 2 – 5 October 2017

Paste composition in wt%

Sample BR slurry GGBFS NFMS CEM I NaOH CaSO40.5H2O plasticizer

GGBFS-B 41 58 0.5 0.8

GGBFS-OPC 41 49 8.2 0.5 1.3

GGBFS-Na 40 56 0.8 0.5 1.9

GGBFS-OPC-Na 40 49 8.1 0.8 0.5 1.6

NFMS-B 33 66 0.4 0.7

NFMS-OPC 33 59 6.6 0.4 1.1

NFMS-Na 32 65 0.6 0.4 1.6

NFMS-OPC-Na 33 59 6.5 0.7 0.4 1.3

ICSOBA Hamburg, 2 – 5 October 2017

ICSOBA Hamburg, 2 – 5 October 2017

ICSOBA Hamburg, 2 – 5 October 2017

Ordinary Portland Cement:

Strength after 2 d: >10 MPa >20 MPa

Strength after 28 d: >32 MPa >52 MPa

ICSOBA Hamburg, 2 – 5 October 2017

10.0 >10 MPa

20.0 >20 MPa

> 10 MPa 43 MPa